Professional Documents
Culture Documents
Bcu 3702
Bcu 3702
Technical Information · GB
6.1.3.2 Edition 11.08
www.kromschroeder.com
2
Table of contents
Burner control unit BCU 370 . . . . . . . . . . . . . . . . . . . . . . . . . 1 3.5 Program status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Table of contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 3.6 Fault message (blinking) . . . . . . . . . . . . . . . . . . . . . . . 34
3.6.1 Reaction to process faults . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Example applications . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 4 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1.1.1 Modulating-controlled forced draught burner . . . . . . . . . . . 6 4.1 Scanning the parameters . . . . . . . . . . . . . . . . . . . . . . . . 41
1.1.2 Modulating-controlled forced draught burner with 4.2 Flame control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
tightness control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 4.2.1 Burner flame signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.1.3 Modulating-controlled forced draught burner with pilot 4.2.2 Burner switch-off threshold . . . . . . . . . . . . . . . . . . . . . . . . 41
burner and tightness control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 4.2.3 UVS check (1× in 24 hours) . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.1.4 Controlling the BCU via PROFIBUS-DP . . . . . . . . . . . . . . . . . . 8 4.3 Behaviour during start-up . . . . . . . . . . . . . . . . . . . . . . 42
1.1.5 Controlling the BCU and the butterfly valve via 4.3.1 Minimum burner pause time tBP . . . . . . . . . . . . . . . . . . . . 42
PROFIBUS-DP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 4.3.2 Burner start-up attempts . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2 Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 4.3.3 Switch-on delay time tE . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.1 PROFIBUS User Organisation . . . . . . . . . . . . . . . . . . . . . 9 4.3.4 Pre-ignition time tVZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.3.5 1st safety time on start-up, burner/pilot burner tSA1 . . . . . 44
3 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 4.3.6 1st flame proving period, burner/pilot burner tFS1 . . . . . . 44
3.1 Connection diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 4.3.7 2nd safety time on start-up, main burner tSA2 . . . . . . . . . 45
3.1.1 BCU 370 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 4.3.8 2nd flame proving period, main burner tFS2 . . . . . . . . . . . 45
3.1.2 BCU 370 with actuator IC 20 . . . . . . . . . . . . . . . . . . . . . . . . 14 4.4 Behaviour during operation . . . . . . . . . . . . . . . . . . . . 46
3.1.3 Capacity control by adjusting the valve between the 4.4.1 Minimum combustion time tB . . . . . . . . . . . . . . . . . . . . . . 46
Open position and a separate Low position . . . . . . . . . . . . . . . 15 4.4.2 Controller enable signal delay time tRF . . . . . . . . . . . . . . 46
3.1.4 BCU 370..B1 with PROFIBUS-DP . . . . . . . . . . . . . . . . . . . . . 16 4.4.3 Safety time during operation tSB . . . . . . . . . . . . . . . . . . . . 46
3.2 BCU 370 program sequence . . . . . . . . . . . . . . . . . . . . 17 4.4.4 Behaviour in the event of flame failure during operation 47
3.2.1 Normal start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 4.4.5 Last fault signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.2.2 Quick start, butterfly valve waits in the Ignition position . 19 4.4.6 V2 during burner operation . . . . . . . . . . . . . . . . . . . . . . . . 48
3.2.3 Quick start, butterfly valve waits in the Closed position . . 21 4.5 Monitoring/tightness control . . . . . . . . . . . . . . . . . . . . 49
3.2.4 Start-up without pre-purge, butterfly valve waits in the 4.5.1 Min. gas pressure monitoring . . . . . . . . . . . . . . . . . . . . . . 49
Closed position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 4.5.2 Digital input function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.2.5 Controlled air flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 4.5.3 Air monitoring during pre-purge . . . . . . . . . . . . . . . . . . . . 49
3.3 Tightness control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 4.5.4 Air monitoring during operation . . . . . . . . . . . . . . . . . . . . 50
3.3.1 Program sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 4.5.5 Tightness test period tP . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.4 PROFIBUS-DP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 4.5.6 Calculation example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.4.1 Configuration, Master-Slave procedure . . . . . . . . . . . . . . . 29 4.6 Air control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.4.2 ddressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 4.6.1 Valve control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.4.3 Network technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 4.6.2 Pre-purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.4.4 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 4.6.3 Quick start starts in ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.4.5 Bus communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 4.6.4 Pre-purge time tPV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
1 Application start which can be activated ensure the high flexibility of the
The BCU 370 burner control unit controls, ignites and moni- burner equipment.
tors industrial forced draught burners of unlimited capacity in The quick-start option allows standard-compliant start-up of
intermittent or continuous operation. the forced draught burner without pre-purge after normal
It can be used for directly ignited forced draught burners or shut-down. This avoids unnecessary admission of air into the
forced draught burners ignited with pilot burner. The BCU 370 combustion chamber. The heat output is available as quickly
activates the fan and sets the connected butterfly valve to Pre- as possible after a temperature demand.
purge and Ignition position. After pre-purge and burner start, t
the Enable signal is issued to an external controller which
positions the butterfly valve in accordance with the output
demand. Post-purge occurs after the end of burner opera-
tion. The burner control unit BCU 370 monitors the gas and air
pressure. An optionally integrated tightness control function
checks the valves with an external gas pressure switch.
Programmability by means of the optical interface and BCSoft
PC software guarantees optimum adaptation to the relevant
application. Adjustable start-up attempts and automatic re-
The program status, the unit parameters and the level of the
flame signal can be read directly from the BCU. An integrated
Manual mode allows manual start of the burner and setting
of the butterfly valve position independently of the central con-
trol system. The BCSoft operator-control and setting software
provides a powerful tool for start-up and servicing.
To reduce the installation and wiring costs Kromschröder of-
fers an optional Profibus-DP interface to transfer the activation
signals and feedbacks.
0 � 90°
90° � 0
19
23 the butterfly valve to pre-purge and igni-
18 tion position. It issues the Enable signal
22 17
9 3 7 4 5 29 30 31 32 13 to the control system after start-up of
DG min DL V1 V2
the burner.
DG
S
VG VG..L
UV
GIK
M
DL
IC 20
B VA
1.1.2 Modulating-controlledforceddraught
BCU 370..I1..D3 25 burner with tightness control
L1 21 28 In addition to controlling the forced
26
draught burner, the burner control unit
24
20 also monitors the fail-safe function of
0 � 90°
90° � 0
19
23
the two solenoid valves for gas via the
18
22 9 3 7 4 11 5 29 30 31 32 13
17 gas pressure switch DG which is set to
DG min DL V1 DG V2 pe/2.
DG Parameter 27 = 1: V2 is “ON” during
DG
S
GIK
M
DL
IC 20
B VA
1.1.3 Modulating-controlledforceddraught
BCU 370..D3 25
burner with pilot burner and tightness
L1 21 28
26 control
24 A pilot burner ignites the main burner
20
0 � 90°
90° � 0
19
23 and is switched off during the main
18 burner’s safety time.
22 17
9 37 45 11 6 29 30 31 32 13
DG min DL V1 V2 DG V3 Parameter 27 = 0: V2 is “OFF”, i.e. in-
terrupted pilot burner, during burner
operation.
DG DG
VG pe/2 GIK
VG..L
S
UV
VG
M
DL
IC 20
B VA
BUS
to the temperature controller for capacity
control. The temperature controller then
Profibus-DP controls the butterfly valve directly.
BCU 370..B1
ϑ
25
28 3PS ϑ
0 � 90°
90° � 0
L1, 26 Temperature
controller
29 30 31 32
L1,
29 30 31 32
2 Certification
EC type-tested and certified
pursuant to
– Gas Appliances Directive (90/396/EEC) in conjunction with
EN 298,
– Low Voltage Directive (73/23/EEC) in conjunction with the
relevant standards,
– Electromagnetic compatibility 89/336/EEC in conjunction
with the relevant standards relating to radiation.
AGA
Approval No. 6478 in preparation
CSA and FM approved
Canadian Standards Association Class: 3335-01 and
3335-81 Systems (Gas-)Automatic Ignition and Components
Factory Mutual Research Class: 7611 Combustion Safe-
guards and Flame Sensing System
Suitable for applications pursuant to NFPA 85 and NFPA 86
BCU 370..I1 V1 C S1 S L A Z M V2 V3 R
0 � 90°
90° � 0
C
F1
F3
s1 r
230V~
l v1 v2 v3 c c r1 s
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 PE N 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
max. 1 A, max. 1 A,
253 V 253 V
V1 p p p I Z M
V2 DL DG DG 3PS
min max
V3
ϑ
L1 (L1)
N (L2)
PE
3 Function
3.1 Connection diagrams
3.1.1 BCU 370
The drawing shows the BCU 370..I1 with integrated ignition
unit, ionisation control and double-electrode operation.
For cable selection and wiring, see Project planning informa-
tion.
For the explanation of symbols, see Legend.
t
3
2 UVS
1
3
2 UVS
1
Z Z
3
2 UVS
1
Z Z
I Z
p pe
2
DG
3PS
L1 (L1)
N (L2)
PE
0 � 90°
90° � 0
90°
0
IC 20
16 15 13 12 11 8 7 6 4 3 2 1
PE
S11 S10
S2 S1
S3 S4
0 � 90°
90° � 0
Standard wiring of BCU 370 and BCU 370..B1 without three-
point step control function
r Valve position Activation of terminal
Upper end position Open 28
25 26 27 28 29 30 31 32 Lower end position Closed 27
Lower end position Low Via separate limit switch
Lower end position Ignition 26
+ –
M
3PS
Min
BCU 370..I1..B1 V1 C S1 S L A Z M V2 V3 R
0 � 90°
90° � 0
C
F1
F3
s1 r
230V~
l v1 v2 v3 c c
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 PE N 24 25 26 27 28 29 30 31 32
V1 p p p I Z M
V2 DL DG DG 3PS
min max
V3
L1 (L1)
N (L2)
PE
BCU 370..B1
ON
OFF
2B 2A 1B 1A
PROFIBUS-DP
3.1.4 BCU 370..B1 with PROFIBUS-DP For the explanation of symbols, see Legend.
Function see “PROFIBUS-DP”
For cable selection and wiring, see Project planning informa-
tion.
08 Normal shut-down
via ϑ signal
00 Start-up position/standby
If parameter P27 = 0:
V2 is switched off
08 Normal shut-down
via ϑ signal
00 Start-up position/standby
Function > BCU 370 program sequence > Quick start, butterfly valve waits in the Closed position 22
08 Normal shut-down
via ϑ signal
00 Start-up position/standby
00 Start-up position/standby
0 � 90°
90° � 0
air flow input, terminal 22 or via PROFIBUS, is activated. Cold
air is fed to the combustion chamber, e.g. for cooling.
r
Following the air pressure switch DL rest position check, the
r1 s BCU 370 starts the fan and opens the butterfly valve to the
N 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 Open position. The pressure switch for air DL monitors the
air pressure.
max. 1 A, max. 1 A, If the start-up signal (J) is applied during controlled air flow,
253 V 253 V
the burner is started. If the elapsed controlled air flow time is
at least as long as the set pre-purge time, the burner starts
immediately after the Ignition position has been approached.
M If it is shorter, the total air volume is supplied until the end of
3PS the pre-purge time.
ϑ Activation of the controlled air flow input is not required for
L1 (L1) normal burner start.
N (L2)
PE Activation of the controlled air flow function during burner
operation will be ignored.
S
VG pe/2 VG..L
UV
GIK eration during post-purge. The pre- and
post-purge times (parameters 18 and 19)
M
must be set so that their duration is at
DL
IC 20 least as long as the test period tP.
B VA
0 � 90°
90° � 0
19
23 checked simultaneously.
18
22 17
9 37 45 11 6 29 30 31 32 13
DG min DL V1 V2 DG V3
DG DG
VG pe/2 GIK
VG..L
S
UV
VG
M
DL
IC 20
B VA
3.4 PROFIBUS-DP
PROFIBUS is a manufacturer-independent, open field bus
standard for diverse applications. PROFIBUS-DP is a bus vari-
ant for communication between automation systems and
distributed peripherals at the field level, optimised for speed
and low connection costs.
On PROFIBUS-DP, the individual bus stations are connected
via a 2-core shielded cable as standard.
3.4.1 Configuration, Master-Slave procedure
PROFIBUS-DP is structured as a Master-Slave system. This
allows mono-master or multi-master systems to be imple-
mented.
A distinction is made between three device types:
– DP Master Class 1 (DPM1)
DPM1 devices are central controllers which exchange
data with the distributed stations (slaves) on the basis of a
defined cycle. This includes, for instance, the PLC, PC, CNC
or VME systems with which the PROFIBUS-DP is operated.
– DP Master Class 2 (DPM2)
DPM2 devices are programming, project planning or
operator-control devices. They are used for configuration
and commissioning of the system or for system operation
and visualisation in ongoing operation.
– DP Slaves
The devices which transmit input information from the
periphery to the master and which issue output informa-
tion from the master to the periphery are referred to as
“slaves”.
This also includes the BCU..B1.
The use of a standard bus system offers massive benefits com- 3.4.3 Network technology
pared to manufacturer-specific bespoke solutions. Time-tested All devices are connected in a bus structure (line). Up to 32 sta-
hardware components, standardised connection methods tions (masters or slaves) can be connected in a single segment.
and a series of tools of bus diagnostics and optimisation are The beginning and end of each segment is fitted with an active
available on the market from a whole range of manufacturers. bus terminator. Both bus terminators must have a permanent
The widespread use of the system ensures that the planning power supply to ensure error-free operation. The bus termina-
and service personnel are very familiar with how the system tor can be switched in the lower section of the unit.
operates and how to handle it and can therefore operate the
system efficiently.
3.4.2 ddressing
A maximum of 126 units (masters and slaves) can be con-
nected to a PROFIBUS-DP system. Each station is assigned an
individual PROFIBUS address which can be set between 0 and
126 using two code switches on the BCU..B1 board.
The left switch sets the tens or hundreds for the address, whilst
the right switch sets the units.
255 steps
Reserved
Open position
4
reached*
Closed position
5
reached*
6 ON
7 Manual mode
Start-up attempts1)
Safety shut-down
Signal status During program step
(terminal)
Fault message
Timeout 25 s
Restart2)
DGmax. (11) drops XX All X
DGmin. (9) drops XX All except tSA1 + tSA2 4) X
not pending after tSA1 04 tSA1 4) 4
not pending after tSA2 06 tSA2 4) 6
DL (7) pending 0 Rest position check 0
not pending 1 Operating position check 1
drops P1 Pre-purge time P
drops A2 Valve moves to Ignition position 2
drops 02 Waiting time 2
drops 03 Pre-ignition time 3
drops 04 tSA1 4
drops 05 tFS1 5
drops 06 tSA2 6
drops 07 tFS2 7
drops H8 Controller enable waiting time 8
t
Start-up attempts1)
Safety shut-down
Signal status During program step
(terminal)
Fault message
Timeout 25 s
Restart2)
DL (7) drops 08 Operation 8
drops C1 Controlled air flow P
ϑ (21) drops XX All except tSA1 + tSA2
drops 04 tSA1 3)
drops 06 tSA2 3)
Safety inter-
drops XX All 6) 50
lock (24)
Flame (13) pending 0 Rest position check 01
pending 1 Operating position check 01
pending P1 Pre-purge time 01
pending A2 Valve moves to Ignition position 01
pending 02 Waiting time 01
not pending after tSA1 04 tSA1 04
drops 05 tFS1 05
drops 06 tSA2 06
drops 07 tFS2 07
drops H8 Controller enable waiting time 08
drops 08 Operation 08
4 Parameters
Adjust-
Description Parameter Value range Default
able1)
Burner flame signal 01 0 – 25 µA
Burner switch-off threshold 02 1 – 20 µA 1 µA v
Last fault signal 03 XX
Air monitoring during pre-purge 04 0 = Off; 1 = On 1
Air monitoring during operation 05 0 = Off; 1 = On 1
0 = Quick start;
Pre-purge 06 1
1 = On each start-up
Burner start-up attempts 07 1 – 4 1
0 = Fault lock-out;
Behaviour in the event of flame failure during operation 08 0
1 = Restart
Safety time during operation tSB 09 1; 2 s 1s
Minimum combustion time tB 10 0 – 250 s 0s
Minimum burner pause time tBP 11 0 – 250 s 0s
1st safety time on start-up, burner/pilot burner tSA1 12 2; 3; 5; 10 s 5s
1st flame proving period, burner/pilot burner tFS1 13 0; 2; 5; 10; 20 s 2s
2nd safety time on start-up, main burner tSA2 14 0; 2; 3; 5; 10 s 3s
2nd flame proving period, main burner tFS2 15 0; 2; 5; 10; 20 s 2s
0 = Unlimited;
Operating time in manual mode 16 1
1 = Limited to 5 minutes
UVS check (1 x in 24 hours) 17 0 = Off; 1 = On 0
Pre-purge time tPV 18 0 – 250 s 30 s
Post-purge time tPN 19 0 – 250 s 0s
Fan run up time tGV 20 0 – 25 s 2s
t
V = Adjustable
= Depends on hardware configuration
4.1 Scanning the parameters On the BCU 370..U1 for use with UVD 1, no switch-off threshold
During operation, the 7-segment display shows the program will be indicated.
status. 4.2.3 UVS check (1× in 24 hours)
The flame signal and all following parameters of the BCU can Parameter 17
be scanned one after the other by repeatedly pressing the Activates an automatic restart of the burner control unit after
Reset/Information button (for 1 second). 24 hours combustion time.
The parameter display is ended 60 seconds after the last time Systems in continuous operation can be restarted every 24
the button is pressed or by switching off the BCU. hours to check UV sensors that are intended for intermittent
The BCU 370 indicates when the mains switch has been operation only.
switched off. This signals standby mode. On the BCU 370.. Parameter 7 = 0: Unlimited burner operation
B1, the bus switch is still operational to maintain the func- Parameter 7 = 1: An automatic restart is activated once every
tion of the communication system. The control outputs of the 24 hours. The restart begins with pre-purge (parameter 06,
BCU (valves, ignition unit) are electrically separated from the “Pre-purge on each start-up” = 1) or starting the burner in the
mains voltage. Ignition position (parameter 06, “Pre-purge on each start-up”
4.2 Flame control = 0).
The time starts each time the start-up signal (ϑ) is applied.
4.2.1 Burner flame signal
Parameter 01 Since the BCU 370 interrupts burner operation autonomously
after 24 hours, it is to be verified whether the process allows
Displays the flame signal in μA. for the resulting break in heat supply.
The BCU measures the flame signal and assesses whether
there is a flame on the basis of the switch-off threshold.
4.2.2 Burner switch-off threshold
Parameter 02
Determines the value from which a flame signal is detected.
In the case of UV control, this value can be increased, should
the burner to be monitored be influenced by other burners.
If the flame signal is lower than the set switch-off threshold,
the BCU will not detect a flame.
The measured flame signal of the system’s “own” burner should
be at least 3 μA (empirical value) higher than the set switch-
off threshold.
4.3 Behaviour during start-up control unit performs a fault lock-out, in case no flame has
formed. The display blinks and shows the cause of the fault.
4.3.1 Minimum burner pause time tBP
Parameter 11 In accordance with EN 746-2 and EN 676 a maximum of four
start-ups are permitted in specific cases if the safety of the
Determines the minimum burner pause time. installation is not impaired. Please note application stand-
To stabilise the burner operation, a minimum burner pause ards.
time tBP can be set independently of the central control sys- NOTE: Only 1 start-up attempt is possible for units with FM or
tem. CSA approval.
If the start-up signal (ϑ) drops after fan start or if a safety shut-
down occurs, a restart is suppressed for the duration of the
minimum burner pause time tBP, which starts to elapse after
expiry of the post-purge time tPN (parameter 19).
4.3.2 Burner start-up attempts
Parameter 07
This defines the maximum number of possible start-up at-
tempts of the burner.
For burners which require several start-up attempts due to
longer pipes for example, the BCU can automatically carry
out several start-up attempts.
Parameter 07 = 1: One start-up attempt
If a safety shut-down takes place during start-up, e.g. on ac-
count of a flame signal failure, a fault lock-out occurs once
the time tSA has elapsed. The display blinks and shows the
cause of the fault.
Parameter 07 = 2 – 4: 2 – 4 start-up attempts
If several start-up attempts are set at the works and if the BCU
performs a safety shut-down during start-up, it closes the
valves after the safety time tSA has expired and attempts to start
up again. Each start-up attempt begins with pre-purge. Once
the last programmed start-up attempt has failed, the burner
00 H0 01 A1 P1 A2 03 04 05 06 07 H8 08 88 00 H0 01 A1 P1 A2 03 04 05 06 07 H8 08 88
1 1
24 24
11 DGmax. 11 DGmax.
9 DGmin. 9 DGmin.
30 90° ➔ 0 30 90° ➔ 0
29 0 ➔ 90° 29 0 ➔ 90°
31 31
32 32
7 DL 7 DL
21 ϑ 21 ϑ
3 3
16 16
13 13
4 V1 4 V1
5 V2 5 V2
6 V3 6 V3
17-18 17-18
19-20 19-20
tE tGV tPV tVZ tZ1 tFS1 tSA2 tFS2 tRF t tE tGV tPV tVZ tZ1 tFS1 tSA2 tFS2 tRF t
tSA1 tSA1
Determines the time between applying the start-up signal (ϑ) The ignition unit is activated.
and initiating the burner start. The ignition spark can stabilise in the air flow during the pre-
When several burners are activated simultaneously, setting ignition time tVZ.
different switch-on delay times tE prevents the fans from start- The valves are still closed during the pre-ignition time tVZ. Fol-
ing at the same time and reduces the load on the power lowing pre-ignition tVZ, the safety time tSA1 starts to elapse.
supply. The valves are opened while the ignition unit continues to
operate.
4.3.5 1st safety time on start-up, burner/pilot burner tSA1 4.3.6 1st flame proving period, burner/pilot burner tFS1
Parameter 12 Parameter 13
00 H0 01 A1 P1 A2 03 04 05 06 07 H8 08 88 00 H0 01 A1 P1 A2 03 04 05 06 07 H8 08 88
1 1
24 24
11 DGmax. 11 DGmax.
9 DGmin. 9 DGmin.
30 90° ➔ 0 30 90° ➔ 0
29 0 ➔ 90° 29 0 ➔ 90°
31 31
32 32
7 DL 7 DL
21 ϑ 21 ϑ
3 3
16 16
13 13
4 V1 4 V1
5 V2 5 V2
6 V3 6 V3
17-18 17-18
19-20 19-20
tE tGV tPV tVZ tZ1 tFS1 tSA2 tFS2 tRF t tE tGV tPV tVZ tZ1 tFS1 tSA2 tFS2 tRF t
tSA1 tSA1
The safety time on start-up tSA1 determines when the pilot Determines the flame proving period of the burner or pilot
burner or burner valves will be closed in the event of flame burner.
signal failure. This time elapses before the BCU starts the next program step
V1 and V2 are opened and the ignition unit is activated as the so as to give the flame time to stabilise.
safety time tSA1 starts to elapse. If no flame signal is pending The flame proving period tFS1 starts to elapse once safety time
after elapse of the safety time tSA1, the BCU performs a safety tSA1 has expired.
shut-down. The valves are closed. The BCU carries out up to
3 further start-up attempts, depending on how parameter 07
“Burner start-up attempts” has been set.
The setting of safety time tSA1 is to be determined on the basis of
the burner capacity, the type of control and the relevant appli-
cation standard, e.g. EN 746-2, EN 676, NFPA 85 or NFPA 86.
4.3.7 2nd safety time on start-up, main burner tSA2 4.3.8 2nd flame proving period, main burner tFS2
Parameter 14 Parameter 15
00 H0 01 A1 P1 A2 03 04 05 06 07 H8 08 88 00 H0 01 A1 P1 A2 03 04 05 06 07 H8 08 88
1 1
24 24
11 DGmax. 11 DGmax.
9 DGmin. 9 DGmin.
30 90° ➔ 0 30 90° ➔ 0
29 0 ➔ 90° 29 0 ➔ 90°
31 31
32 32
7 DL 7 DL
21 ϑ 21 ϑ
3 3
16 16
13 13
4 V1 4 V1
5 V2 5 V2
6 V3 6 V3
17-18 17-18
19-20 19-20
tE tGV tPV tVZ tZ1 tFS1 tSA2 tFS2 tRF t tE tGV tPV tVZ tZ1 tFS1 tSA2 tFS2 tRF t
tSA1 tSA1
The safety time on start-up tSA2 determines when the main Determines the flame proving period of the main burner in
burner valves will be closed in the event of flame signal fail- pilot/main burner combinations.
ure. This time elapses before the BCU starts the next program step
V3 is opened as the safety time tSA2 starts to elapse. One so as to give the flame time to stabilise.
second before the end of the safety time tSA2, V2 is closed The flame proving period tFS2 starts to elapse once safety time
(parameter 27 = 0, “Interrupted pilot burner”) or remains open tSA2 has expired.
(parameter 27 = 1, “Permanent pilot burner”). If no flame signal
is pending after elapse of the safety time tSA2, the BCU performs
a safety shut-down. Valves V1, V2 and V3 are closed. The BCU
carries out up to 3 further start-up attempts, depending on
how parameter 07 “Start-up attempts, burner/pilot burner”
has been set.
The setting of safety time tSA2 is to be determined on the basis of
the burner capacity, the type of control and the relevant appli-
cation standard, e.g. EN 746-2, EN 676, NFPA 85 or NFPA 86.
4.4 Behaviour during operation Defines the time between start-up of the burner and control-
ler enable.
4.4.1 Minimum combustion time tB
Parameter 10 The controller enable signal delay time ensures a stable com-
bustion process, e.g. through uniform heating of the entire
Defines the minimum burner combustion time. combustion chamber.
To stabilise the burner operation, a minimum combustion time The time tRF starts to elapse
can be set independently of the central control system.
after expiry of if
If the start-up signal (ϑ) drops once the first safety time tSA1
tSA1 tFS1 = 0, tSA2 = 0
has started to elapse, the burner remains in operation for at
least time tB. The minimum combustion time tB starts to elapse tFS1 tSA2 = 0
following controller enable. If the start-up signal drops before tSA2 tFS2 = 0
the first safety time tSA1, e.g. during pre-purge, the control unit tFS2 tFS1 > 0, tSA2 > 0, tFS1 > 0
reverts directly to standby and the burner is not ignited. The BCU shows program status H8 . After time tRF has elapsed,
the BCU closes the operation signalling contact (terminals
4.4.2 Controller enable signal delay time tRF
17/18) and activates controller enable (terminal 25).
Parameter 29
4.4.3 Safety time during operation tSB
00 H0 01 A1 P1 A2 03 04 05 06 07 H8 08 88 Parameter 09
1
24 Defines the safety time during operation tSB for valves V1, V2
11 DGmax. and V3.
9 DGmin.
30 90° ➔ 0 If there is a flame failure while the burner is operating, the
29 0 ➔ 90°
31 BCU closes the valves within the safety time during operation
32
7 DL tSB. The default in accordance with EN 298 is 1 s. The safety
21 ϑ time during operation tSB can also be set to 2 s. Prolonging
3
16 the time increases the installation availability in the case of
13
4 V1 brief-duration fades of the flame signal.
5 V2
6 V3 The safety time of the installation during operation (including
17-18
19-20 closing time of the valves) may not exceed in accordance with
tE tGV tPV tVZ tZ1 tFS1 tSA2 tFS2 tRF t EN 746-2 3 s, in accordance with NFPA 85 and NFPA 86 4 s.
tSA1
Please note application standards.
4.4.4 Behaviour in the event of flame failure during operation 4.4.5 Last fault signal
Parameter 08 Parameter 03
Determines whether a restart will be attempted following a The BCU shows the last fault message.
safety shut-down during operation. In order to analyse a burner system, the last fault message
For burners with occasionally unstable flame signals during can be called up. In addition, parameters 81 to 90 show the
operation, a one-off restart can be attempted. last 10 messages. Extended diagnostics is possible using the
Parameter 08 = 0: Fault lock-out after installation fault. BCSoft software.
In the event of an installation fault (e.g. flame failure or air
pressure failure), the burner control unit performs a fault lock-
out within the safety time during operation tSB. This involves
disconnecting the power from the gas valves. The fault sig-
nalling contact closes, the display blinks and shows the cur-
rent program status (see tables Program status and Fault
messages).
Parameter 08 = 1: Restart after installation fault.
If the BCU detects an installation fault (e.g. flame failure) after
the second flame proving period has elapsed, the valves are
closed and the operation signalling contact is opened within
time tSB. The burner control unit now attempts to restart the
burner once. The restart begins with pre-purge. For further
restart attempts, the burner must have been operational for
at least 2 seconds.
If the burner does not function, a fault lock-out occurs. The
display blinks and shows the cause of the fault.
In accordance with EN 746-2 and EN 676 a restart may be
attempted under certain conditions. The safety of the system
must not be impaired. Please note application standards.
– Check of the HIGH signal (air monitoring signal activated) 4.5.4 Air monitoring during operation
Once the fan has been activated, the BCU checks whether Parameter 05, if activated, parameter 04 “Air monitoring dur-
the air monitor switches while the actuator moves to the ing pre-purge” is also activated.
Open position (start-up with pre-purge) or during the This parameter determines whether the air pressure is moni-
waiting time (quick start). The signal to input DL must be tored during burner operation.
switched to HIGH. If the HIGH signal is not applied, the To ensure that there is actually air pressure during burner
BCU performs the set number of further start-up attempts operation, the pressure can be monitored using the air moni-
(parameter 07) after a delay time of 25 seconds has toring during operation function.
elapsed. If no further start-up attempts have been param-
eterised, a fault lock-out occurs and fault message 1 , Parameter 05 = 0: No air monitoring during operation. A de-
“No air supply during start-up”, is displayed. crease in the air pressure or a failure in air supply will not be
detected.
Air pressure must be present and a HIGH signal must be ap-
plied to input DL during the subsequent pre-purge. If the HIGH Parameter 05 = 1: The air pressure is monitored during opera-
signal is not applied, the BCU performs a safety shut-down tion. During burner start (after pre-purge until the end of the
once the delay time of 25 seconds has elapsed. If no further main burner safety time tSA2) and during burner operation
start-up attempts have been parameterised (parameter 07), (after the end of main burner flame proving period tFS2 until
a fault lock-out occurs and fault message P , “No air supply the end of normal operation), the air must flow and a HIGH
during pre-purge”, is displayed. signal must be applied to input DL. If the HIGH signal drops,
the BCU performs a safety shut-down.
Depending on the application standard, different air monitor-
ing methods are possible. Along with pressure monitoring, – DL signal drops during burner start.
other functions such as fail-safe feedback signals from the If further start-up attempts have been parameterised (pa-
actuator or air flow monitoring devices may be required. Please rameter 07), a further burner start-up attempt is made. If
note application standards. no further start-up attempts have been parameterised, a
fault lock-out occurs and fault message X , “No air pres-
sure on DL in program step X”, is displayed.
– DL signal drops during burner operation.
If a restart is parameterised (parameter 08), a one-off
burner restart is attempted. If the restart option is not acti-
vated, a fault lock-out occurs and fault message X , “No
air pressure on DL in program step X”, is displayed.
19
23
18
22 17
9 3 7 4 11 5 29 30 31 32 13
DG min DL V1 DG V2
DG
S
VG pe/2 VG..L
UV
GIK
M
DL
IC 20
B VA
4.6.4 Pre-purge time tPV If tightness control is activated (BCU..D3, parameter 24 = 3),
Parameter 18 the pre-purge time tPV must be set to at least the value of the
test period (parameter 26).
00 H0 01 A1 P1 A2 03 04 05 06 07 H8 08 88 The pre-purge time tPV is to be set on the basis of the relevant
1
24 application standard (e.g. EN 676, EN 746-2, NFPA 85 or NFPA
11 DGmax. 86).
9 DGmin.
30 90° ➔ 0
29 0 ➔ 90°
31
32
7 DL
21 ϑ
3
16
13
4 V1
5 V2
6 V3
17-18
19-20
tE tGV tPV tVZ tZ1 tFS1 tSA2 tFS2 tRF t
tSA1
Determines how long the full air flow will be supplied to the
combustion chamber before burner start.
Pre-purge removes non-combusted gases from the combus-
tion chamber.
The pre-purge time tPV starts once the actuator has signalled
the Open position and the air pressure switch DL contact has
closed.
If “Pre-purge on each start-up” is deactivated (parameter 06
= 0), pre-purge is omitted on burner start after a normal shut-
down within the last 24 hours.
If the pre-purge time tPV is set to 0 s, pre-purge is always
omitted, e.g. even on restart after a safety shut-down. The
BCU carries out a quick start on each burner start. The butterfly
valve is moved to the Ignition position via the Open position
after normal shut-down.
4.6.5 Post-purge time tPN The actuator moves to the Closed position after the end of the
Parameter 19 post-purge time tPN.
Quick start (parameter 06 = 0) or pre-purge time = 0 (param-
08 P9 A0 00 88 eter 18 = 0):
1
24 After the post-purge time tPN has elapsed, the actuator moves
11 DGmax. to the Open position and then to the Ignition position (param-
9 DGmin.
30 90 � 0 eter 28 = 0) or the Low position (parameter 28 = 1).
29 0 � 90
31 If tightness control is activated (BCU..D3, parameter 24 = 3)
32
7 DL and quick start is activated (parameter 06 = 0), the post-purge
21 ϑ
3 time must be set to at least the value of the test period (pa-
16 rameter 26).
13
4 V1
5 V2
6 V3
17-18
19-20
tPN t
00 H0 01 A1 P1 A2 03 04 05 06 07 H8 08 88
1
24
11 DGmax.
9 DGmin.
30 90° ➔ 0
29 0 ➔ 90°
31
32
7 DL
21 ϑ
3
16
13
4 V1
5 V2
6 V3
17-18
19-20
tE tGV tPV tVZ tZ1 tFS1 tSA2 tFS2 tRF t
tSA1
0 � 90°
90° � 0
r
25 26 27 28 29 30 31 32
Parameter 32 = 1: When bit 7 is activated, the butterfly valve Definition of the modulation range following controller
moves to the Low position. For this purpose, terminal 25 is enable
wired to a fourth limit switch in the actuator. BCU..B1-3 with three-point step control function
Valve position Output byte
Upper end position Open Bit 6
Lower end position Closed Bit 7, parameter 32 = 0
0 � 90°
90° � 0
Bit 7, parameter 32 = 1,
Lower end position Low terminal 25 wired to sepa-
r
rate limit switch
Lower end position Ignition Bit 7, parameter 32 = 2
25 26 27 28 29 30 31 32
M
Min
4.10 Password
4.10.1 User-defined password
Parameter 30, 4-digit number
Password saved to protect parameter settings.
To prevent unauthorised changes to parameter settings, a
password is stored in parameter 30. Changes to parameter
settings can only be made once this number has been entered.
The password can be changed using BCSoft. Note the effect of
parameter settings on the safe functioning of your system.
The password set at the factory can be found in the delivery
note supplied.
5 Selection
BCU 370: For modulating-controlled forced draught burners
W Q I1 I2 I3 F E U0 U1 D1 D3 B1* -3*
BCU 370 v v v v v v
= standard, v = available
* If “none”, this specification is omitted.
Order example
BCU 370WI1FEU0D1
6.3 Controlling the butterfly valve 6.6 Protecting the ignition unit from overload
The required burner commissioning time depends on the The BCU protects the integrated ignition unit and the electronic
running time of the butterfly valve actuator. switch from overload. Excessive switching triggers a warning
The BCU 370 waits for the feedback signal to indicate that the signal (blinking 53 ). After the minimum cycle time has elapsed,
actuator has reached the Open position, for instance, before the BCU starts.
the pre-purge time is started. The minimum cycle time saved in the BCU can be calculated
The Ignition position is always approached via the Open posi- using the formula:
tion. Minimum cycle time = (tVZ + tSA1 - 1) x 6
Once the butterfly valve has been set to the relevant position, Example:
a plausibility check takes place. The related control output is Pre-ignition time tVZ = 2 s,
switched off briefly. The feedback signal must drop accord- 1st safety time on start-up t
SA1 = 3 s
ingly.
(2 s + 3 s - 1) x 6 = 24 s
6.4 Safety interlock (Limits) In this example, the BCU 370 may not be started more often
The limiters in the safety interlock (linking of all the relevant than every 24 s.
safety control and switching equipment for the use of the ap- If an external ignition unit/transformer is being used, the for-
plication, for example STB [safety temperature limiter]) must mula is as follows:
isolate terminal 24 from the voltage supply. If the safety in-
Minimum cycle time = (tVZ + tSA1 - 1) x 2
terlock is interrupted, the display shows a blinking 50 as a
warning signal. The program sequence is interrupted. All Adjust the minimum burner pause time tPB (parameter 11)
of the BCU 370’s outputs are disconnected from the electri- correspondingly, if required.
cal power supply. The burner control unit restarts when the
6.7 Wiring
safety interlock is switched on again and the start-up signal
(J) activated. The BCU is suitable for hard wiring only. Do not reverse phase
and neutral conductor. Different phases of a three-phase cur-
6.5 Too many remote resets rent system must not be installed at the inputs. Do not connect
If a remote reset is made 5 times in 15 minutes (terminal 23 or voltage to the outputs.
by bus signal), the BCU is locked, shows fault message 10 , On BCU 370..B1 for PROFIBUS-DP, no voltage may be connected
“Too many remote resets”, and can only be reset by pressing to terminals 17 – 23. Otherwise, the BCU may be damaged.
the Reset/Information button.
6.7.1 Single-electrode operation with external ignition unit 6.10 Contact protection devices
The safety-related switch contacts on the BCU 370, e.g. for
BCU 370 13 14 15 16 PE N actuation of the gas solenoid valves, are protected by an
internal fuse. This fuse cannot be replaced, since safe open-
ing of the contacts is not guaranteed following overload or
a short-circuit, e.g. due to a wiring fault. The BCU must be
returned to the manufacturer for repair.
6.11 Installation
Recommended installation position: vertical (cable glands
pointing downwards).
Detach the upper section of the BCU, remove and screw on
If a burner only has one electrode, which is used for ignition
lower section with four screws Ø 4 mm. Replace upper section
and ionisation control, an external ignition transformer must
and screw into place.
be used, e.g. TZI or TGI.
Contact rating:
Valves: Max. 1 A, cos j = 1,
Butterfly valves: Max. 1 A, cos j = 1,
Ignition: Max. 1 A, cos j = 0.3,
Controller enable signal: Max. 1 A, cos j = 1,
the contacts may be loaded with a max. total of 2.5 A,
Fan: Max. 3 A, start-up current: Max. 6.5 A < 1 s.
The outputs may be loaded with a max. total of 4 A.
Operation and fault signalling contacts:
Dry Contact, max. 1 A, 253 V, not fused internally.
Reset/Information button: Max. number of operating cycles:
1000.
Fuse in BCU, replaceable, F1: T 5A H, pursuant to
IEC 60127-2/5.
Permissible UV sensors:
Elster Kromschröder models UVS 1, 5, 6, 8 and UVD 1.
Weight: Approx. 1.8 kg.
9.1 PROFIBUS-DP
Manufacturer ID: 0x08EC.
ASIC type: SPC3.
SYNC- and FREEZE-capable.
Baud rate detection: Automatic.
Min. cycle time: 0.1 ms.
Diagnostic bytes: 6 (DP Standard).
Parameter bytes: 7 (DP Standard).
C
D
E: BCU label with the most important status messages in
English
E Additional stickers in D, F, I, NL and E enclosed
50
90
154
185
ø5
138
10 Legend
88 Display
88 Blinking display
Ready
Safety interlock (Limits)
Start-up signal
Controlled air flow
Ignition transformer
Gas valve
Flame signal
Operating signal
Fault signal
Reset
Input signal
Output signal
Flame simulation check
Pressure switch
p (DL for air, DG for gas)
Ignition/Ignition position
Three-point step controller
M
Actuator (in connection diagram)
12 Annex
12.1 Status and fault messages for PROFIBUS-DP
This table can be used to program the master.
Input bytes (BCU ➔ master)
Byte 2 Byte 0, Bit 2 = 0 (Status message) Byte 0, Bit 2 = 1 (Fault message)
0 0 Start-up position/standby
1 A0 Valve moves to Closed position 01 Flame simulation
2 01 Fan run up time
3 A1 Butterfly valve moves to Open position
4 P1 Pre-purge time 04 Start-up without flame signal
5 A2 Butterfly valve moves to Ignition position 05 Flame failure during 1st flame proving period
6 03 Pre-ignition time 06 Flame failure during 2nd safety time
7 04 1st safety time on start-up 07 Flame failure during 2nd flame proving period
8 05 1st flame proving period 08 Flame failure during operation
9 06 2nd safety time on start-up
10 07 2nd flame proving period d0 Fault Air monitor break contact check
11 08 Controller enable signal d1 Fault Air monitor make contact check
12 P9 Post-purge time d2 Fault Air supply while butterfly valve moves to Ignition position
13 d3 Fault Air supply during pre-ignition time
14 d4 Fault Air supply during 1st safety time on start-up
15 d5 Fault Air supply during 1st flame proving period
16 d6 Fault Air supply during 2nd safety time on start-up
17 d7 Fault Air supply during 2nd flame proving period
18 d8 Fault Air supply during operation
19 dP Fault Air supply during pre-purge time
t
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Remarks
Kromschröder AG
Michael Rehkamp
m.rehkamp@kromschroeder.com
Osnabrück
03250520
www.kromschroeder.com
www.elster.com